Industrial Air Filter Device with Automatic Replacement and Cleaning
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Solution Overview
Problem
Industrial air filters in machines like power magnetics cabinets become dirty, reducing cooling efficiency and motor drive performance, as existing methods for cleaning or replacing them are complex and inefficient, leading to prolonged use of degraded filters.
Innovation Solution
An air filter device with a first operation unit to supply new filters and a second operation unit to collect used filters, along with a control unit that determines when filters need replacement and includes a dirt removal unit to clean used filters, maintaining filter performance over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If air filters are installed in inlet and outlet to prevent dirt from adhering to heat dissipator and fan motor, then cooling efficiency is improved, but the filters become dirty and require frequent replacement which complicates operation and reduces productivity
Solution Approach 1:
The air filter device performs self-cleaning through automatic dirt removal mechanisms including reverse airflow generation and vibration excitation. The system monitors its own filter status and initiates cleaning operations without external intervention, eliminating the need for manual replacement while maintaining cooling efficiency.
Solution Approach 2:
The device implements periodic cleaning cycles where the filter is automatically cleaned at predetermined time intervals or when dirt accumulation reaches a threshold level. This periodic maintenance restores filter performance without requiring continuous manual intervention, balancing cooling efficiency with operational productivity.
2Reliability
If high pressure air is jetted to the air filter to remove dirt, then filter performance is temporarily restored, but dirt is not completely removed and performance gradually deteriorates over time
Solution Approach 1:
The system performs preliminary cleaning actions before the filter performance significantly deteriorates. By monitoring dirt accumulation levels and initiating cleaning operations proactively, the system prevents complete clogging and extends the operational service life of the filter while maintaining consistent performance.
Solution Approach 2:
The cleaning mechanism uses dynamic vibration and alternating airflow patterns that adapt to the accumulated dirt level. The vibration frequency and airflow intensity are adjusted based on real-time filter status, enabling progressive removal of entrenched dirt particles that static cleaning methods cannot eliminate.
3Reliability
If manual replacement of air filters is implemented, then clean filters are supplied, but the operation is significantly complicated and likely to be neglected
Solution Approach 1:
The system automatically monitors filter status, generates cleaning commands, and executes dirt removal operations without requiring manual intervention. The control unit tracks filter usage, detects when cleaning is needed, and activates the appropriate cleaning mechanism, making the entire filter maintenance process self-service and eliminating operational complexity.
Solution Approach 2:
The device incorporates feedback mechanisms that continuously monitor filter dirt accumulation levels and provide status information to the control unit. This feedback enables the system to automatically determine when cleaning is required and verify when cleaning is complete, ensuring filter cleanliness without complex manual operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The air filter device ensures constant performance by automatically supplying new filters and reusing cleaned filters, preventing dirt entry and enhancing cooling efficiency and motor drive reliability.
Implementation Method 1
a dirt removal unit which removes dirt adhered to the used air filter
Data Source
AI summary
An air filter device of an industrial machine in which an air filter is arranged in a filtered portion of the industrial machine is provided, the air filter device includes: a first operation unit which transports the long air filter toward the filtered portion; a second operation unit which collects the air filter transported from the first operation unit and used in the filtered portion; and a control unit which controls the drive of the first operation unit and the second operation unit and the control unit includes a first determination unit which determines whether or not the air filter in the first operation unit is about to run out or runs out, and outputs, when the first determination unit determines that the air filter is about to run out or runs out, a signal indicating that the air filter needs to be replaced.